Diverter arm and method

ABSTRACT

A system for aligning items, such as bottles, includes a rotating plate and a diverter arm that extends outward over a top surface of the plate towards the plate edge. A rotating channel may surround the plate. In operation, bottles are dropped onto the plate and rotated by the plate against the arm. The distance between the top surface of the arm and the plate surface is such that the arm generally diverts the bottles outward and guides them into free gaps within the channel. The distance is also configured such that as bottles back-up, waiting for free channel gaps, the arm allows any buckling bottles to pass over and back onto the plate, rather than into the channel. The distance may also be configured such that the arm acts like a scoop. As bottles back-up behind the arm, the arm presses under the bottles along the arm and passes them over, relieving the pressure.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to systems and methods for aligningrandomly oriented items and more particularly, to an arm-like structureand the use thereof for aligning randomly oriented items.

2. Description of the Art

Systems are generally known for taking a plurality of items, such asbottles, that are supplied in a random and disorderly fashion and forordering and aligning these items for subsequent processing. Forexample, referring to the Figures in which like reference numerals referto like elements, there is shown in FIG. 1 and FIG. 2 a top view and aside view, respectively, of an example prior art unscrambling system 100that orders and aligns “randomly oriented” bottles so that as thebottles leave system 100, they are disposed in a row with their tops andbottoms facing one another in an end-to-end fashion. In thisorientation, subsequent systems, such as stand-up unit 116, can standthe bottles on end so that the bottles can be subsequently filled andcapped.

More specifically, example system 100 includes a tub 102 with an opening102 a on its top side and an additional opening 102 b along its exteriorwall. A rotating plate 104 is situated within tub 102 and is connectedto motor 108, which causes the plate to freely rotate within the tub. Inthis example system, a second rotating plate 106 is situated beneathplate 104 and is also connected to motor 108, which causes this plate torotate. Plate 104 has a smaller diameter than plate 106 and is spacedabove plate 106, thereby forming a channel 110 between the outerperimeter of plate 104 and the inner perimeter of tub 102. Through therotation of plate 106, items situated within channel 110 move (i.e.,rotate) around the inner perimeter of tub 102.

In operation, a hopper 112 and conveyor 114 mechanically feed randomlyoriented bottles 120 into tub 102 and onto rotating plate 104 (e.g., asshown by bottles 122). As plate 104 rotates, it causes bottles 122 tomove towards the outward perimeter of the tub and into channel 110 suchthat once in the channel, the bottles are aligned with their tops andbottoms facing one another (e.g., as shown by bottles 124). Once in thisorientation, rotating plate 106 moves the bottles towards opening 102 b,where the bottles exit tub 102 and enter bottle stand up unit 116, forexample, where the bottles are subsequently stood on end (e.g., as shownby bottles 126).

Overall, the intent of bottle unscrambling systems like that of system100 is to maximize the number of aligned bottles exiting tub 102. Assuch, system 100 needs to ensure that a maximum number of properlyaligned bottles are situated within channel 110 at all times.Accordingly, system 100 needs to maximize the movement of random bottlesfrom plate 104 into channel 110 and needs to ensure these bottles areproperly aligned once within the channel.

Prior bottle unscrambling systems like system 100, however, have theproblem that as random bottles enter tub 102, they often remain on plate104 and fail to move towards the outer perimeter of the tub. To overcomethis problem, prior systems have increased the rotational speed of plate104 to help force the bottles outward. While this solution solves theproblem of moving bottles off plate 104, the increased rotational speedof plate 104 often causes the bottles to move outward too fast. As aresult, bottles do not enter the channel in an orderly fashion and tendto bunch-up, thereby impeding the movement of bottles intoopen/available spaces within the channel. In addition, the increasedspeed of the bottles leaving plate 104 often causes the bottles to enterthe channel even when space is not available, resulting in the bottlesoverlapping and stacking upon bottles already in the channel. As aresult, these overlapping bottles must be removed from the channel priorto exiting the system at opening 102 b.

Other prior systems have addressed the problem of bottles remaining onplate 104 by replacing plate 104 with a rotating circular cone thatangles downward towards channel 110. In general, the conical shape ofthe rotating cone naturally moves bottles from the center of the conetowards channel 110. However, this solution also tends to move thebottles outward too fast, resulting in the same problems as justdescribed.

Still other systems, such as those described, for example, in U.S. Pat.No. 3,910,407 by Walter Sterling, U.S. Pat. No. 5,443,149 by NorbertRohwetter et al., and U.S. Pat. No. 4,362,234 by Walter McDonald et al.,have used an arm-like structure to move items (e.g., bottle tops andbottles) from a rotating plate (like plate 104) towards the plate'souter perimeter. In these example systems, the arm-like structureresides in a stationary position over the surface of the rotating plateand essentially extends radially outward towards the outer perimeter ofthe plate. As the plate rotates, items on the surface of the plate movetowards the arm, which blocks the items' forward movement and causes theitems to move outward. In the systems described by Sterling andRohwetter, the items are guided off the plate and towards an outerchannel. In the system described by McDonald, the items are guided to anouter periphery of the plate and are aligned along an outer wall of thesystem.

Nonetheless, these systems continue to experience the problem of itemsbecoming overlapped (either within the channel or along the outer wallof the system) and use other mechanisms to further resolve this problem.For example, in the system disclosed by Sterling, a rail is inserted ata spaced distance above the channel, which rail shields overlappingbottle caps from entering the channel. Air jets subsequently move theseoverlapping caps back onto the rotating plate. In the system disclosedby Rohwetter, a motorized/spinning brush is placed over the channel. Thebrush moves overlapping bottles situated in the channel back onto therotating plate. In the system disclosed by McDonald, container caps arepassed through a limited height opening that removes any overlappingcaps.

In still other bottle-aligning systems that have used an arm-likestructure to guide bottles off a rotating plate and into a channel, aproblem experienced is that as the arm blocks the bottles and thebottles wait to enter available openings in the channel, the bottlestend to bunch-up and buckle, thereby impeding the movement of thebottles into available openings within the channel. In addition, becausethe bottles buckle, they tend to enter the channel overlapping andstacking upon bottles already in the channel.

SUMMARY

Accordingly, it is desirable to provide an unscrambling system foraligning items, such as bottles, that overcomes the above and otherdisadvantages of the prior art. According to an example embodiment ofthe present invention, a diverter arm is situated within an unscramblingsystem such that the arm extends radially outward over a top surface ofa rotating plate, for example, and diverts bottles situated on the platetowards the system's outer perimeter where the bottles are aligned.Unlike prior arm-like structures that have been used to direct itemsoutward, however, the diverter arm of the present invention does notcompletely block the forward movement of bottles as they rotate on theplate. Rather, the diverter arm of the present invention only impedesthe forward motion, continuing to direct bottles outward but alsoallowing the bottles to flow over the arm as an increased number ofbottles collect behind the arm.

Specifically, according to an example embodiment of the invention, anunscrambling system includes two parallel rotating plates, one at aspaced distance above the other, with the top plate being smaller thanthe bottom plate. In this way, the two plates form a recessed channelaround the perimeter of the top plate, the channel acting as an aligningmechanism. Situated over the top surface of the top plate is a diverterarm of the present invention that extends from the center of the plate,for example, outward to approximately the plate's outer perimeter, forexample. Alternatively, the diverter arm may extend in two or moredirections towards the top plate's outer perimeter. The top side or topsurface of the diverter arm is configured at a distance above thesurface of the top plate (also referred to as the height of the diverterarm). Preferably, this distance is uniform over the length of thediverter arm. The arm preferably remains in a stationary positionrelative to the plate.

According to an example embodiment of the invention, the top plate maybe interchangeable, for example, with other plates of varying diameters,thereby varying the width of the channel. The diverter arm may also beinterchangeable, for example, so that the length of the arm can be setto correspond to the radius/diameter of the top plate currently in use.According to another aspect of the invention, the height of the diverterarm may be adjustable to correspond to the size of the bottles beingaligned, for example.

According to an example embodiment of the invention, randomly orientedbottles are initially dropped onto the surface of the top plate.Generally, the bottles will land on their sides. Through the rotation ofthe top plate, some bottles may move outward and into the channel, wherethe bottles are aligned with their bottoms and tops facing one anotherand are subsequently discharged from the system through the rotation ofthe bottom plate. Other bottles, however, will rotate in a forwarddirection with the top plate and will contact the diverter arm, forexample.

According to an example embodiment of the invention, the height of thediverter arm is configured such that the arm impedes the forward motionof the bottles and guides/diverts these bottles outward towards thechannel. The bottles will remain along the arm until a gap isencountered in the channel, at which point the arm will guide thebottles into this gap.

Unlike the arm structures of prior systems, however, the diverter arm ofthe present invention is not a wall-like structure that blocks allforward movement of the bottles. Rather, the height of the diverter armallows some bottles to pass over the arm. Specifically, assuming spaceis not immediately available in the channel, multiple bottles may beginto bunch-up around the diverter arm, for example. As bottles continue toback-up, the increased pressure on the bottles may cause some bottles tobuckle upward, for example, relative to the top plate. According to anexample embodiment of the invention, rather than continuing to blockthese buckling bottles and forcing these bottles outward to the channel,the height of the diverter arm is configured such that the bucklingbottles extend above the top side of the diverter arm. In this position,the diverter arm is no longer able to divert the bottles and the bottlesget pushed over the arm and back onto the surface of the top plate.Here, the passed bottles continue in a forward direction either movingoutward and into the channel or back around to the diverter arm.

In addition to simply allowing buckled bottles to pass over the arm,according to an example embodiment of the invention, the height of thediverted arm is also configured such that the arm pro-activelyalleviates bottle-necks behind the arm. Specifically, the height of thearm is configured such that as flat lying bottles, for example,initially contact the arm, the pressure exerted on these bottles by therotating top plate is sufficient to cause the bottles to divert outward,but is not sufficient to cause the bottles to divert upward relative tothe arm. As an increased number of bottles begin to back-up behind thearm, however, the pressure on the bottles along the arm will naturallyincrease. As this pressure increases on the bottles along the arm, thesebottles will find it easier to move over the arm, rather than along thearm. As such, the arm will begin to act like a scoop, for example,pushing under these bottles and causing them to buckle and pass over thearm and back onto the plate.

Advantageously, because the diverter arm of the present invention allowsbuckling bottles to move up and over the arm rather than completelyblocking their forward motion, the bunching up of bottles behind the armis relieved, thereby allowing bottles to more freely enter the channeland fill available openings. In addition, rather than the bucklingbottles entering the channel and thereby overlapping and stacking uponone another, buckling bottles by-pass the channel and continue forward.As a result, a diverter arm according to an example embodiment of theinvention increases the flow of bottles moving from the plate towardsthe channel while also preventing the bunching and buckling of bottlesalong and within the channel and as such, increases the number ofproperly aligned bottles that reside in the channel.

According to another example embodiment of the invention, anunscrambling system includes a single rotating plate surrounded by astationary wall that acts as an aligning mechanism. Situated over thetop surface of the plate is a diverter arm of the present invention thatextends from the center of the plate, for example, outward towards theplate's outer perimeter, for example. Here, bottles are dropped onto theplate and diverted outward towards the wall such that the bottles alignalong the wall with their bottoms and tops facing one another. As such,a spaced gap exists between the end of the diverter arm and the innerperimeter of the wall to allow bottles to pass between the arm and wall.As an example, this spaced gap can correspond to the approximate widthof a single bottle. In this way, the diverter arm causes a single row ofaligned bottles to form around the inner perimeter of the wall.

Similar to above, the diverter arm according to this example embodimentof the invention is configured to have a height above the surface of theplate such that the arm does not function as a wall-like structure thatblocks all forward movement of bottles on the plate. Rather, the heightis configured so that the diverter arm only impedes this forwardmovement and allows buckling bottles to pass over the arm and in afurther aspect, is configured so that the arm operates as a scoop-likestructure, for example, as described above.

Other features and advantages of the present invention will becomeapparent from the following description of the invention, which refersto the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a top plan view of a prior art system that aligns andorders randomly oriented bottles through a rotating plate and a rotatingchannel.

FIG. 2 shows a side plan view of the prior art system illustrated byFIG. 1.

FIG. 3A shows a side plan view of an example diverter arm according tothe present invention where the diverter arm is incorporated into anexample system that aligns and orders randomly oriented bottles throughthe use of a rotating plate and a rotating channel.

FIG. 3B is a side plan view of a section of the example diverter arm andsystem illustrated by FIG. 3A.

FIG. 4 shows a top plan view of the example diverter arm and systemillustrated by FIG. 3A.

FIGS. 5A and 5B show further example diverter arms according to thepresent invention.

FIGS. 6A, 6B, and 6C illustrate an example operation of a diverter armaccording to the present invention.

FIG. 7A shows a top plan view of an example diverter arm according tothe present invention where the diverter arm is incorporated into anexample system that aligns and orders randomly oriented bottles along awall of the system.

FIG. 7B shows a side plan view of a section of the example diverter armand system illustrated by FIG. 7A.

DESCRIPTION OF THE EMBODIMENTS

For purposes of illustrating example embodiments of the presentinvention, the invention will be described using bottles as an exampleitem to be aligned and ordered. However, one skilled in the art willrecognize that the diverter arm of the present invention is alsoapplicable, for example, to systems that align/order other items, suchas tops to bottles.

Referring now to FIGS. 3A and 4, there is illustrated an examplediverter arm 320 according to an example embodiment of the presentinvention, the diverter arm being shown as part of example bottleunscrambling system 300. Note that FIG. 3A shows a side plan view ofdiverter arm 320 and system 300 and FIG. 4 shows a top plan view ofdiverter arm 320 and system 300. Reference will first be made to examplesystem 300 and then to example diverter arm 320 and an example operationthereof.

As shown, example system 300 includes tub 302, top plate 312, feederplate 314, motor 308, and diverter arm 320. Tub 302 includes circularfeeder ring 304 and base plate 306, which is located at a bottom side ofthe tub and is fixably connected to feeder ring 304. Tub 302 is openalong its top side 302 a and also includes an opening 302 b along feederring 304 (note that opening 302 b is beneath wiper motor 318 asillustrated in FIG. 4). Motor 308 includes a shaft 310 that freelyextends up through base plate 306 and into tub 302.

Top plate 312 and feeder plate 314 are situated inside tub 302 and liein parallel planes, for example, one on top of the other, with eachplate parallel to and above the plane formed by base plate 306. Feederplate 314 is approximately the same diameter as feeder ring 304, forexample, while top plate 312 has a diameter selected to be smaller thanthat of feeder plate 314. In operation, the centers of plates 312 and314 are inserted over shaft 310 such that the shaft extends up througheach plate. Spacers 322 are inserted between the two plates therebydefining a height/distance between the two plates. This arrangement oftop plate 312, feeder plate 314, and spacers 322 is interlocked to shaft310 through screw knob 324, for example, thereby causing motor 308 tofreely rotate both plates within tub 302 As shown in this examplesystem, top plate 312 and spacers 322 are interchangeable (although theydo not need to be) through the removal and insertion of screw knob 324,thereby allowing different top plates 312, with varying diameters, anddifferent spacers 322, with varying heights, to be inserted into thesystem.

Accordingly, based on the size of top plate 312 and the height ofspacers 322, a variable height and width channel 316 is formed betweenthe outer perimeter 312 a of plate 312 and the inner perimeter of feederring 304. Feeder ring 304 and perimeter edge 312 a of top plate 312 formthe edges/sides of this channel while the surface of feeder plate 314forms the bottom surface of the channel.

As further described below, in an example operation of system 300according to an example embodiment of the invention, bottles entersystem 300 onto the surface of top plate 312 and generally land on theirsides (e.g., as shown by bottles 342 and 344). As plate 312 rotates,these bottles move towards and eventually contact diverter arm 320(e.g., as shown by bottles 346), which guides the bottles outward fromplate 312 and into channel 316. Channel 316 then causes the bottles toalign with their tops and bottoms facing one another (e.g., as shown bybottles 340). As such, the width of channel 316, which is determined bythe diameter of top plate 312, is set, for example, to correspond to thesmallest width of the bottles to be aligned (e.g., see bottles 340 a inFIG. 3A). Such a width ensures multiple bottles do not enter the channellying next to one another. Similarly, the height of the channel, whichis determined by spacers 322, is set, for example, such that the bottlesfall into the channel and such that the bottles also extend partiallyabove the surface of top plate 312 when within the channel (e.g., seebottles 340 a in FIG. 3A). In this way, the bottles in channel 316create a small ridge that extends above the surface of top plate 312,thereby preventing multiple bottles from easily entering and stackingwithin the channel, for example. Once the bottles are in channel 316,feeder plate 314 moves the bottles around the inner perimeter of feederring 304 towards opening 302 b where the bottles are discharged forsubsequent processing. Note that the feeder ring may also include wearstrip 330 along the circumference of the channel to ensure bottles arenot scrapped as the move through the system.

Note further that rather than forming a rotating top plate andcorresponding rotating channel using two rotating plates, as describedin example system 300, one skilled in the art will recognize that thereare other ways to form such a structure and any such structure may beused. For example, rather than using two plates, system 300 may includeonly a single plate molded to include a recessed channel around theouter perimeter thereof.

Turning now to example diverter arm 320, according to an exampleembodiment of the present invention the arm is situated in tub 302 andresides over the top surface of top plate 312, with end 320 a of the armextending outward towards the plate's outer perimeter 312 a. As seen inFIG. 3B, which is an expanded view of a section of FIG. 3A, the top side(or top surface) 320 f of diverter arm 320 is at a distance 320 c abovethe surface of top plate 312 and forms a plane that is parallel, forexample, to the surface of top plate 312 (i.e., the distance 320 c isuniform, for example, across the length of the diverter arm). Accordingto an example embodiment of the invention, unlike top plate 312 andfeeder plate 314, diverter arm 320 remains in a stationary positionwhile system 300 operates. In general, note that the diverter arm may becoated with a finishing, for example, to prevent the arm from scratchingbottles that contact the arm.

As illustrated in FIGS. 3A, 3B, and 4, example diverter arm 320 has apronounced width 320 d and is relatively thin, thereby forming apronounced space above top plate 312. In addition, as furtherillustrated in FIG. 4, example diverter arm 320 extends from the centerof plate 312 outward, in one direction, in a semi-arc like fashion, withthe arc bending/pointing towards the direction of rotation of top plate312. One skilled in the art will recognize, however, that othervariations and shapes of diverter arm 320 are possible without deviatingfrom the present invention. For example, rather than extend outward fromthe center of top plate 312, diverter arm 320 may originate from aposition offset from the plate's center. In addition, rather than havean arc-like shape, the diverter arm may extend straight outward. Also,rather than extend in only a single direction towards perimeter 312 a oftop plate 312, the diverter arm may extend in two or more directionstowards the plate's perimeter (as represented by the dotted portion 320e of the diverter arm in FIG. 4, for example). Furthermore, rather thanbeing a thin arm that forms a pronounced space above top plate 312, thediverter arm may extend to the surface of the top plate, for example, asshown by the side view of example diverter arm 320 in FIG. 5A, forexample. In addition, rather than having a pronounced width 320 d,diverter arm 320 may have a relatively thin width, for example, as shownby the top-down-view of example diverter arm 320 in FIG. 5B, forexample.

Referring again to FIG. 3A, when connecting example diverter arm 320 toexample system 300, a diverter arm spacer 326, for example, may beinserted between the diverter arm and top plate 312, this spacerdefining the height/distance 320 c between the top side or top surface320 f of the diverter arm and the surface of top plate 312. Thecombination of this spacer and the diverter arm is inserted over shaft310 such that the shaft extends up through the spacer and arm. Thediverter arm and spacer are then secured to system 300 through screwknob 324. As indicated, according to an example embodiment of theinvention, the diverter arm remains stationary during operation and assuch, shaft 310 does not interconnect the arm to motor 308.

As further illustrated in FIGS. 3A and 4, example diverter arm 320 isalso secured to example system 300 through mounting bracket 328,diverter support screw 330, and support knob 332, although othermounting mechanisms may be used. Here, mounting bracket 328 is attachedto feeder ring 304 and extends towards the center of tub 302perpendicular to feeder ring 304. Support screw 330 is attached to end320 b of diverter arm 320 (e.g., by using a screw and nut), and extendsperpendicularly upward from the arm and through an installation slot 328a in mounting bracket 328. Support screw 330 is then secured to mountingbracket 328 through support knob 332.

According to an example embodiment of the invention and as illustratedby example system 300, example diverter arm 320 may be interchangeable,similar to top plate 312, so that the length of the arm can be set tocorrespond to the radius of the top plate 312 currently being used. Forexample, the length of diverter arm 320 may extend approximately orsubstantially to the outer perimeter 312 a of top plate 312, as shown byexample system 300.

Note further that according to an example embodiment of the invention,the distance 320 c between the diverter arm's top side 320 f and thesurface of top plate 312 may also be adjustable. In example system 300,this adjustment is made by interchanging diverter arm spacer 326 and byadjusting support knob 332 to vary the vertical height of support screw330. As further described below, this height 320 c is purposely selectedbased on the dimensions of the bottles to be aligned and ordered. Oneskilled in the art will recognize, however, that there are other ways toset the distance 320 c between top side 320 f of the diverter arm andthe surface of top plate 312. For example, rather than use spacer 326and a thin diverter arm as shown in FIG. 3A, the diverter arm can have avertical width equal to the height 320 c, as shown in FIG. 5A, forexample. One skilled in the art will also recognize that the ability tointerchange the length and height of the diverter arm is not specific tothe invention and a fixed length/height diverter arm can also be used.

Turning now more specifically to the distance 320 c between the diverterarm's top side (or top surface) 320 f and the surface of top plate 312,unlike the arm structures of prior systems, the diverter arm accordingto an example embodiment of the invention is not a wall like structurethat blocks all forward movement of bottles on the surface of top plate312 as the bottles rotate against the arm. Rather, the distance 320 c issuch that arm 320 only impedes the forward movement of these bottles anddoes not necessarily prevent the bottles from passing over the arm. Morespecifically, as an increased number of bottles begin to back-up behindthe diverter arm as bottles wait to enter channel 316, the increasedpressure caused by these additional bottles and the rotation of plate312 may cause some bottles to buckle upward, for example. Rather thancontinuing to block these buckling bottles and to force these bottlesoutward to channel 316 as in prior systems, according to an exampleembodiment of the invention the distance 320 c that the diverter armextends above top plate 312 is such that these buckling bottles nowextend above the upper edge of top side 320 f of the arm, for example.As a result, these bottles get diverted/pushed up and over the arm.

More specifically, the distance 320 c between top surface 320 f of thediverter arm and the surface of top plate 312 is set, for example, suchthat for those bottles that are lying substantially flat on their sidesagainst top plate 312, a substantial portion of the bottles extendsabove the arm, as shown in the side view of diverter arm 320 in FIG. 6A,for example. In this orientation, a sufficient portion of the bottles isstill below top side 320 f of the diverter arm so that as these flatlying bottles contact the diverter arm, the arm diverts the bottlesoutward to the channel as shown, for example, in the top-down view ofFIG. 6B. However, as an increased number of bottles begin to back-upbehind the diverter arm, some bottles may buckle upward, for example.Because a substantial portion of the bottles naturally lies above thediverter arm, as these bottles buckle, they will extend to a heightabove the arm (e.g., above height 320 c) so that the arm is no longerable to divert them outward. At this point, the continued rotation oftop plate 312, for example, pushes the bottles over the arm as shown inFIG. 6C, for example (note that in FIG. 6C the diverter arm is extendingdirectly outward from the Figure).

In addition to simply allowing buckled bottles to pass over the arm,according to an example embodiment of the invention, the distance 320 cof the arm is set such that the arm also pro-actively alleviatesbottle-necks behind the arm. Specifically, the distance 320 c is setsuch that as flat lying bottles, for example, initially contact the arm,the pressure exerted on these bottles by rotating plate 312 issufficient to cause the bottles to divert outward, but is not sufficientto cause the bottles to divert upward relative to the arm. As anincreased number of bottles begin to back-up behind the arm, however,the pressure on the bottles along the arm will naturally increase. Asthis pressure increases on the bottles along the arm, these bottles willfind it easier to move over the arm, rather than along the arm. As such,the arm will begin to act like a scoop, for example, pushing under thesebottles and causing them to buckle and pass over the arm (i.e., rotatingtop plate 312 will push these bottles over the arm). In this way, thediverter arm not only diverts bottles outward, but also assists inalleviating bottle-necks.

Turning now to an overall example operation of system 300 and diverterarm 320, according to an example embodiment of the invention randomlyoriented bottles are initially dropped onto the surface of top plate312, as shown in FIG. 4 (e.g., see bottles 342). As indicated, thesebottles will generally land on their sides. Through the rotation ofplate 312, some bottles may move outward and into channel 316. Otherbottles, however, will rotate in a forward direction (i.e., in acircular path) with plate 312 (e.g., see bottles 344) and willeventually contact diverter arm 320, for example, as shown by bottles346. As indicated, the height 320 c of the arm is set to impede theforward motion of the bottles 346. As such, the arm will initiallyguide/divert these bottles outward towards channel 316 as plate 312continues to rotate. As specified, bottles 340 within the channel extendabove top plate 312, for example, forming a small ridge. As such,bottles 346 will remain along the arm until a gap is encountered in thechannel, at which point the arm will guide the bottles into this gap. Assuch, the diverter arm according to an example embodiment of theinvention, diverts bottles from plate 312 outward to the channel.

Referring now to FIG. 6C, assuming space is not immediately available inchannel 316, multiple bottles may begin to bunch-up around the diverterarm 320, for example. As bottles continue to back-up, the increasedpressure on the bottles may cause some bottles to buckle upward, forexample, relative to top plate 312 and diverter arm 320, as shown byFIG. 6C. Because the diverter arm has a reduced height 320 c relative tothe bottles lying flat on plate 312, the arm does not completely blockall forward motion of the bottles, as described earlier. As such, thesebuckling bottles rise to a height above the diverter arm, for example,such that the continued rotation of plate 312 pushes the bottles up andover the arm rather than into the channel. Similarly, as describedabove, the height of the arm can also be set such that the arm operateslike a scoop, for example, to help alleviate any back-up. Regardless,the bottles that pass over the arm then return to the surface of topplate 312 and continue in a forward direction either moving outward andinto channel 316 through the rotation of top plate 312 or rotating backaround to the diverter arm and continuing as described above.

Continuing with FIG. 4, once the bottles are in channel 316 (e.g., seebottles 340), feeder plate 314 rotates the bottles towards opening 302 bin feeder ring 304. Residing over opening 302 b is wiper motor 318, forexample, that contacts the bottles in the channel and directs them outof tub 302, through opening 302 b, to subsequent systems for processing.Note further that system 300 may also include fiber optic eye 334 alongchannel 316 that detects the presence/absence of bottles in the channel.When the channel is empty, the eye causes additional random bottles tobe dropped onto top plate 312 for aligning.

Advantageously, because the diverter arm of the present invention allowsbuckling bottles to move up and over the arm rather than completelyblocking their forward motion, the bunching up of bottles behind the armis relieved, thereby allowing bottles to more freely enter the channeland fill available openings. In addition, rather than the bucklingbottles entering the channel and thereby overlapping and stacking uponone another, buckling bottles by-pass the channel and continue forward.As a result, a diverter arm according to an example embodiment of theinvention increases the flow of bottles moving from plate 312 towardschannel 316 while also preventing the bunching and buckling of bottlesalong and within the channel and as such, increases the number ofproperly aligned bottles that reside in the channel.

Note that as shown in FIG. 3A, example system 300 is tilted to one side,in the direction along which the diverter arm radially extends towardsthe perimeter of plate 312. Such orientation may assist in divertingbottles outward along diverter arm 320. Nonetheless, note that system300 may also reside in a flat orientation.

Referring now to FIG. 7A, there is illustrated example diverter arm 720according to an example embodiment of the present invention. Here,diverter arm 720 is illustrated in combination with example bottleunscrambling system 700. In general, note that example system 700 issimilar to example system 300 but does use an outer channel 316 to alignand order items, such as bottles. Rather, example system 700 now usesthe inner perimeter of the tub's feeder ring 304, for example, toperform the aligning and ordering of bottles, as described below.

Specifically, example system 700 includes a tub 302 with circular feederring 304, a single rotating top plate 712 rather than two plates thatform a channel as describe above, and example diverter arm 720. Thediameter of plate 712 is approximately the same diameter as feeder ring304, for example, extending towards the inner perimeter of the ring.Similar to above, plate 712 connects to a shaft and motor that freelyrotates the plate within the tub.

As for diverter arm 720, according to an example embodiment of theinvention, the arm is similar to arm 320 and resides within tub 302 overthe top surface of top plate 712, with end 720 a of the arm extendingoutward towards the inner perimeter of feeder ring 304. A space 720 gexists between the end 720 a of diverter arm 720 and the insideperimeter of feeder ring 304 to allow bottles to pass between the armand ring. As indicated, in example system 700, bottles are aligned alongthe inner perimeter of feeder ring 304. As such, space 720 g is neededto allow bottles to pass beyond the diverter arm. As an example, space720 g can correspond to the approximate width of a single bottle. Inthis way, the diverter arm causes a single row of aligned bottles toform around the inner perimeter of the feeder ring.

Note that although example diverter arm 720 is shown in FIG. 7A ashaving a particular shape and form, one skilled in the art willrecognize that other variations and shapes for the arm are possible, aswas described for arm 320, without deviating from the present invention.Also, similar to example arm 320, diverter arm 720 can interconnect tosystem 700 such that it is interchangeable in length and height tocorrespond to the size/shape of the bottles being aligned. Nonetheless,one skilled in the art will again recognize that diverter arm 720 neednot be adjustable in height and length.

Turning now to FIG. 7B, there is seen a side view of a section ofexample system 700, and in particular, a section of example diverter arm720 and top plate 712. Like diverter arm 320, the top surface 720 f ofdiverter arm 720 is set at distance 720 c above the surface of top plate712 and forms a plane that is parallel, for example, to the surface oftop plate 712. Again, according to an example embodiment of theinvention, the distance 720 c that arm 720 extends above the surface ofplate 712 is such that arm 720 does not function as a wall-likestructure that blocks all forward movement of bottles on top plate 712.Rather, height 720 c is set so that diverter arm 720 only impedes thisforward movement and allows buckling bottles to pass over the arm and ina further aspect, is set so that the arm operates as a scoop-likestructure, for example, as described above.

Turning now to an example operation of diverter arm 720, according to anexample embodiment of the invention randomly oriented bottles areinitially dropped onto the surface of top plate 712 and will generallyland on their sides (e.g., see bottles 742). Through the rotation ofplate 712, some of these bottles may move towards the outer perimeter ofthe plate and align along feeder ring 304. Other bottles, however, willrotate in a forward direction with plate 712 (e.g., see bottles 744) andwill eventually contact diverter arm 720, for example, as shown bybottles 746. Like arm 320, the height 720 c of arm 720 is set to impedethe forward motion of bottles 746. As such, arm 720 will initiallyguide/divert these bottles outward towards the end 720 a of the arm. Thebottles will remain in this position until a gap is encountered alongthe inner perimeter of feeder ring 304, at which point diverter arm 720will guide the bottles into this gap, passing the bottles between thearm and ring and thereby aligning the bottles along the perimeter of thering (e.g., see bottles 740). Once aligned, plate 712 rotates thebottles towards opening 302 b in feeder ring 304, where the bottles aredirected out of tub 302 for subsequent processing.

Assuming, however, that space is not immediately available along ring304, multiple bottles may begin to bunch-up around arm 720. As bottlescontinue to back-up, the increased pressure may cause some bottles tobuckle upward, for example, relative to top plate 712 and diverter arm720. Again, because of the diverter arm's reduced height 720 c relativeto the bottles lying on the surface of the plate, the continued rotationof plate 712 pushes these buckling bottles up and over the arm, therebyrelieving the back-up and preventing buckling bottles from aligningalong the ring. Similarly, the height of the arm can also be set suchthat the arm operates like a scoop, for example, to help alleviate theback-up. Regardless, the bottles that pass over the arm then return tothe surface of top plate 712 and continue in a forward direction, eithermoving outward towards the perimeter of ring 304 through the rotation oftop plate 712 or rotating back around to the diverter arm and continuingas described above.

Although the present invention has been described in relation toparticular embodiments thereof, many other variations and modificationsand other uses will become apparent to those skilled in the art. It ispreferred, therefore, that the present invention be limited not by thespecific disclosure herein.

1. A system for aligning items, comprising: a plate having an outer edgeand a top surface, wherein the plate is intended to accept the items onthe top surface and to move the items through the system; a diverter armwith a length and a top side, the diverter arm residing over the topsurface of the plate and extending substantially over its length towardsthe outer edge of the plate, the top side of the diverter arm and thetop surface of the plate substantially having a uniform distance overthe length of the diverter arm; and wherein the distance between thediverter arm top side and the top surface of the plate is configuredsuch that the diverter arm impedes and diverts items restingsubstantially flat on the top surface of the plate but passes underitems that are angled upward relative to the top surface of the plate.2. The system of claim 1, wherein the diverter arm guides the impededand diverted items towards the outer edge of the plate.
 3. The system ofclaim 1, wherein the distance between the diverter arm top side and thetop surface of the plate is further configured such that the diverterarm causes one or more items resting substantially flat on the topsurface of the plate to raise upward relative to the top surface of theplate and to move over the diverter arm when sufficient pressure isexerted against the one or more items.
 4. The system of claim 1, whereinthe diverter arm further extends substantially over its length inmultiple directions towards the outer edge of the plate.
 5. The systemof claim 1, wherein the distance between the diverter arm top side andthe top surface of the plate is adjustable depending on dimensions ofthe items.
 6. The system of claim 1, wherein the items are bottles. 7.The system of claim 1, wherein the diverter arm extends over its lengthsubstantially to the outer edge of the plate.
 8. The system of claim 1,further comprising a channel surrounding the outer edge of the plate andintended for aligning the items.
 9. The system of claim 8, wherein adiameter of the plate defines a width of the channel and wherein theplate is interchangeable thereby creating a variable width channel. 10.The system of claim 9, wherein the diverter arm is interchangeable tocorrespond to the plate.
 11. The system of claim 1, wherein the diverterarm extends over its length to a distance less than the outer edge ofthe plate so that at least one item can fit between an end of thediverter arm and the outer edge of the plate.
 12. The system of claim 1,wherein the system is tilted towards a direction in which the diverterarm extends towards the outer edge of the plate.
 13. A system foraligning items, comprising: a plate having an outer perimeter and a topsurface, wherein the items are intended to initially rest on the topsurface of the plate and the plate is intended to move the items thoughthe system; a diverter arm with a length and a top side, the diverterarm residing over the top surface of the plate and extendingsubstantially over its length towards the outer perimeter of the plate;and wherein the top side of the diverter arm and the top surface of theplate are configured to have a distance based on dimensions of the itemssuch that when a first pressure is exerted on items near or contactingthe diverter arm, the near or contacted items move along the length ofthe diverter arm towards the outer perimeter of the plate and when asecond pressure, greater than the first pressure, is exerted on theitems near or contacting the diverter arm, the near or contacted itemspass over the diverter arm.
 14. The system of claim 13, furthercomprising an aligning mechanism surrounding the outer perimeter of theplate and intended for aligning the items; and wherein the diverter armguides the near or contacted items that move along the length of thediverter arm towards the aligning mechanism.
 15. The system of claim 14,wherein the aligning mechanism is a channel.
 16. The system of claim 15,wherein a diameter of the plate defines a width of the channel andwherein the plate is interchangeable thereby creating a variable widthchannel.
 17. The system of claim 16, wherein the diverter arm isinterchangeable to correspond to the plate.
 18. The system of claim 14,wherein the aligning mechanism is a wall perpendicular to and extendingabove the top surface of the plate.
 19. The system of claim 13, whereinthe system is tilted towards a direction in which the diverter armextends towards the outer perimeter of the plate.
 20. A method fordiverting items, comprising the steps of: moving the items through arotation of a plate, a plurality of the items resting substantially flaton a surface of the plate; impeding the movement of the items through adiverter arm such that at least one of the items becomes angled upwardrelative to the surface of the plate; diverting, through the diverterarm, the movement of at least one of the plurality of items resting flaton the surface of the plate such that the at least one diverted itemmoves towards an edge of the plate; passing over the diverter arm the atleast one item that is angled upward; and continuing to move through therotation of the plate the at least one passed item.
 21. The method ofclaim 20, wherein for said impeding step the diverter arm causes the atleast one item to angle upward relative to the surface of the plate bymoving under the at least one item.
 22. The method of claim 20, whereina substantially uniform distance exists between a top side of thediverter arm and the surface of the plate, said method furthercomprising prior to said moving step the step of adjusting the distancebased on dimensions of the items.
 23. The method of claim 20, whereinthe items are bottles.
 24. The method of claim 20, wherein saiddiverting step further comprises diverting the at least one diverteditem towards an aligning mechanism at the edge of the plate.
 25. Themethod of claim 24, wherein the aligning mechanism is either a wallperpendicular to and extending above the surface of the plate or achannel.